Knockdown furniture assembly and method for making same

ABSTRACT

A knockdown furniture assembly includes a frame releasably connected to two arm pieces. Each arm piece has a bottom rail having two carriage bolts extending outward therefrom for positioning in the frame. The bolts are held in place on the arm pieces and the frame by washer and nut assemblies. The washer and nut assemblies are countersunk in the rails to allow for a flush connection between the rails and the frame. The arm pieces can be easily disassembled from the frame by disengaging the washer and nut assemblies and removing the frame from off of the bolts.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The invention relates to a furniture assembly, particularly for anupholstered sofa or futon, that can be easily assembled and disassembledby the user with minimal tools. The invention provides a knockdownfurniture assembly that maintains strength and stability.

Several furniture manufacturers in the United States produce upholsteredgoods that can be disassembled for shipping and moving, and thenreassembled at their final destination. Such knockdown furniture hastypically used arm pieces having threaded inserts that accept boltsextending from a frame piece. However, after several years of use theinserts wallow out of the hole in which they are set causing thefurniture to become unstable and ultimately unusable. In an effort toovercome and eliminate the aforementioned problems, the presentinvention was conceived.

SUMMARY OF THE INVENTION

Therefore it is an object of the present invention to provide afurniture piece that can be disassembled into separate pieces fortransporting in small areas, and easily reassembled at the ultimatedestination.

It is another object of the invention to provide an upholsteredknockdown furniture piece that retains stability and strength overtime.

It is yet another object of the invention to provide a knockdownfurniture piece that can be easily assembled with minimal tools.

These and other objectives of the present invention are achieved byproviding a knockdown furniture assembly having a first arm piece withat least one connecting member extending outward therefrom and a framehaving at least one aperture therein for receiving the connectingmember. The connecting member is adapted for releasable engagement inthe frame aperture so that the arm piece is releasably connected to theframe.

According to one preferred embodiment of the invention, the arm pieceincludes a rail defining at least one opening for positioning theconnecting member therethrough.

According to another preferred embodiment of the invention, theconnecting member comprises a carriage bolt inserted through the openingin the rail and held in place on the rail by frictional engagement witha first releasable fastening assembly.

According to yet another preferred embodiment of the invention, thefirst fastening assembly comprises a flat washer, a lock washer and anut for positioning on the connecting member.

According to yet another preferred embodiment of the invention, the railincludes a side facing the frame having a countersunk area adjacent theopening for positioning the first fastening assembly so that the rail ispositionable in flush engagement with the frame.

According to yet another preferred embodiment of the invention, thecarriage bolt is positioned within the aperture of the frame and held inplace within the frame by frictional engagement with a second releasablefastening assembly so that the arm piece is releasably connected to theframe.

According to yet another preferred embodiment of the invention, the armpiece can be disconnected from the frame by disengaging the secondfastening assembly and withdrawing the carriage bolt from the aperturein the frame.

According to yet another preferred embodiment of the invention, a secondarm piece is releasably connected to the frame.

According to yet another preferred embodiment of the invention, theframe is rectangular, and the first arm piece and the second arm pieceare connected at opposite sides of the frame.

According to yet another preferred embodiment of the invention, aseating support is mounted on the frame.

According to yet another preferred embodiment of the invention, a backsupport is mounted on the frame.

According to yet another preferred embodiment of the invention, each armpiece includes two connecting members extending outward therefrom.

According to yet another preferred embodiment of the invention, thefurniture assembly is a sofa, futon or chair, and the arm piece includesan armrest.

An embodiment of the method for making a knockdown furniture assemblyaccording to the invention includes providing an arm piece having anleast one opening, and inserting a connecting member through the armpiece opening and fastening the connecting member to the arm piece byfrictionally engaging the connecting member with a releasable fasteningassembly. A frame having an aperture for receiving the connecting memberis provided. The connecting members are inserted through the frameaperture and the connecting member is fastened to the frame byfrictionally engaging the connecting member with a second releasablefastening assembly so that the arm piece and the frame are releasablyconnected.

According to yet another embodiment of the invention, the arm piece isupholstered so as to leave the opening and the connecting memberexposed.

According to yet another embodiment of the invention, the frame isupholstered so as to leave the aperture exposed.

According to yet another embodiment of the invention, the arm piece andthe frame are upholstered such that areas of the arm piece and the framethat contact each other are left exposed.

Another embodiment of the method for making a knockdown furnitureassembly according to the invention includes providing an arm piecehaving a rail defining a first opening and a second opening, andinserting a first carriage bolt through the first arm piece opening andinserting a second carriage bolt through the second arm piece opening.The first and second carriage bolts are fastened to the arm piece byfrictionally engaging the first and second carriage bolts with a firstand second washer and nut assemblies. A frame having a first apertureand a second aperture for receiving the first carriage bolt and thesecond carriage bolt are provided. The first carriage bolt is insertedthrough the first frame aperture, and the second carriage bolt is putthrough the second frame aperture. The carriage bolts are fastened tothe frame by frictional engagement with washer and nut assemblies.

According to yet another embodiment of the invention, the arm piece isupholstered such that the carriage bolts remain exposed.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the objects of the invention have been set forth above. Otherobjects and advantages of the invention will appear as the inventionproceeds when taken in conjunction with the following drawings, inwhich:

FIG. 1 is a perspective view of a knockdown furniture assembly accordingto a preferred embodiment of the invention;

FIG. 2 is a partial, exploded view of the knockdown furniture assemblyof FIG. 1;

FIG. 3 is a partial perspective view of the furniture assembly of FIG.1;

FIG. 3A is a partial cross sectional view of the furniture assemblyviewed along line 3A in FIG. 3;

FIG. 4 is a perspective view of the furniture assembly of FIG. 1, with aseating support for a futon mounted on the frame; and

FIG. 5 is a perspective view of the knockdown furniture assembly of FIG.4, shown upholstered.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

Referring now specifically to the drawings, a preferred embodiment ofthe knockdown furniture assembly according to the present invention isillustrated in FIG. 1, and shown generally at reference numeral 10. Thefurniture assembly 10 generally comprises a frame 11 releasablyconnected to two arm pieces 12, 13. The frame 11 is preferablyrectangular with sides 11 a-d, and the arm pieces 12, 13 are positionedon opposite sides 11 a, 11 d of the frame 11. The frame 11 and armpieces 12, 13 are preferably made of wood.

Each arm piece 12, 13 is identical, and therefore, only one arm piece 12will be described in detail. As shown in FIG. 2, arm piece 12 comprisestwo vertical members 12 a, 12 b, joined together by a horizontal toprail 12 c, and a double bottom rail 12 d. Two holes 13, 14 are formed inthe bottom rail 12 d of the arm piece 12. Carriage bolts 15, 16 areinserted into the holes 13, 14, and fastened to the rail 12 d bytightening suitable fasteners, such as flat washers 17, lock washers 18and nuts 19, on the carriage bolts 15, 16. The fasteners 17, 18, 19 arecountersunk in the rail 12 d to allow for a flush connection between therail 12 d and the frame 11.

At this point, the arm pieces 12 can be upholstered. When upholsteringthe arm piece 12, the side of the rail 12 d facing the frame 11 is leftunupholstered, and the heads of the carriage bolts 15, 16 on theopposite side of the rail 12 d are also left exposed. The heads of thecarriage bolts 15, 16 are uncovered so that the carriage bolts 15, 16can be removed or replaced during future reupholstering if necessary.

The frame 11 is upholstered separately from the arm pieces 12, 13. Thesurfaces of sides 11 a, 11 d, facing the arm pieces 12, 13 are leftunupholstered.

Sides 11 a, 11 d of the frame 11 are identical, and therefore only side11 d will be discussed in detail. As shown in FIG. 2, two apertures 20,21 are drilled into frame side 11 d. The exposed sections of thecarriage bolts 15, 16 extending outward from the rail 12 d are insertedinto the apertures 20, 21 of the frame side 11 d and fastened bytightening flat washers 22, lock washers 23 and nuts 24, as shown inFIGS. 2, 3 and 3A.

A seating support 25, such as for a futon as shown in FIG. 4, is mountedon the frame 11. Both the frame 11, and the arm pieces 12, 13 areupholstered at this point, and the seating support 25 is upholstered toform the upholstered furniture assembly 10 shown in FIG. 5. The finishedfurniture assembly 10 is sturdy and strong, and can be easilydisassembled for delivery through into lofts and small rooms. Forexample, arm piece 12 can be disconnected from the frame 11 bydisengaging the fasteners 22-24 and withdrawing the carriage bolts 15,16 from the apertures 20, 21 in frame side 11 d. The identical processis used to disconnect arm piece 13 from frame side 11 a. With the armpieces 12, 13 separated from the frame 11, the frame 11 and the armpieces 12, 13 can be more easily transported through door openings,hallways, stairwells and other narrow passages. The frame 11 and armpieces 12, 13 can be reassembled by simply repeating the steps describedabove.

In an alternative embodiment, the furniture assembly is a sofa with anupholstered back piece. In such an embodiment, the arm pieces include avertical member having holes to accept carriage bolts that are insertedinto a second frame positioned vertically. The second frame is connectedto the vertical members of the arm pieces in the same manner asdescribed above for frame 11 and bottom rail 12 d. The upholstered backpiece of the sofa is mounted in the second frame.

A knockdown furniture assembly and a method for making same is disclosedabove. Various embodiments of the invention can be made withoutdeparting from its scope. Furthermore, the foregoing description of thepreferred embodiment of the invention and the best mode for practicingthe invention are provided for the purpose of illustration only and notfor the purpose of limitation—the invention being defined by the claims.

1. A knockdown furniture assembly comprising: (a) a first arm piecehaving at least one connecting member extending outward therefrom; and(b) a frame defining at least one aperture therein for receiving saidconnecting member, said connecting member adapted for releasableengagement in the frame aperture whereby said arm piece is releasablyconnected to said frame.
 2. A furniture assembly according to claim 1,wherein said arm piece includes a rail defining at least one opening forpositioning said connecting member therethrough.
 3. A furniture assemblyaccording to claim 2, wherein said connecting member comprises acarriage bolt inserted through the opening in said rail and held inplace on said rail by frictional engagement with a first releasablefastening assembly.
 4. A furniture assembly according to claim 3,wherein said first fastening assembly comprises a flat washer, a lockwasher and a nut for positioning on said connecting member.
 5. Afurniture assembly according to claim 3, wherein said rail includes aside facing said frame having a countersunk area adjacent the openingfor positioning said first fastening assembly therein, whereby said railis positionable in flush engagement with said frame.
 6. A furnitureassembly according to claim 3, wherein said carriage bolt is positionedwithin the aperture of said frame and held in place within said frame byfrictional engagement with a second releasable fastening assembly,whereby said arm piece is releasably connected to said frame.
 7. Afurniture assembly according to claim 6, wherein said arm piece can bedisconnected from said frame by disengaging said second fasteningassembly and withdrawing said carriage bolt from the aperture in saidframe.
 8. A furniture assembly according to claim 1, further comprisinga second arm piece releasably connected to said frame.
 9. A furnitureassembly according to claim 8, wherein said frame is rectangular, andsaid first arm piece and said second arm piece are connected at oppositesides of said frame.
 10. A furniture assembly according to claim 1,further comprising a seating support mounted on said frame.
 11. Afurniture assembly according to claim 1, further comprising a backsupport mounted on said frame.
 12. A furniture assembly according toclaim 1, wherein said first arm piece includes two connecting membersextending outward therefrom.
 13. A furniture assembly according to claim1, wherein said furniture assembly comprises a sofa, futon or chair, andfurther wherein said arm piece comprises an armrest.
 14. A method formaking a knockdown furniture assembly comprising the steps of: (a)providing an arm piece defining an least one opening formed therein; (b)inserting a connecting member through the arm piece opening andfastening the connecting member to the arm piece by frictionallyengaging the connecting member with a first releasable fasteningassembly; (c) providing a frame defining an aperture for receiving theconnecting member; and (d) inserting said connecting member through theframe aperture and fastening the connecting member to the frame byfrictionally engaging the connecting member with a second releasablefastening assembly whereby said arm piece and said frame are releasablyconnected.
 15. A method according to claim 14, further comprising thestep of mounting a seating segment on the frame.
 16. A method accordingto claim 14, further comprising the step of upholstering the arm pieceso as to leave the opening and the connecting member exposed.
 17. Amethod according to claim 14, further comprising the step ofupholstering the frame so as to leave the aperture exposed.
 18. A methodaccording to claim 14, further comprising the step of upholstering thearm piece and the frame such that areas of the arm piece and the framethat contact each other are left exposed.
 19. A method for making afurniture assembly comprising the steps of: (a) providing an arm piecehaving a rail defining a first opening and a second opening formedtherein; (b) inserting a first carriage bolt through the first arm pieceopening and inserting a second carriage bolt through the second armpiece opening; (c) fastening each of the first and second carriage boltsto the arm piece by frictionally engaging the first and second carriagebolts with a first and second washer and nut assemblies; (d) providing aframe defining a first aperture and a second aperture for receiving thefirst carriage bolt and the second carriage bolt; and (e) inserting thefirst carriage bolt through the first frame aperture and the secondcarriage bolt through the second frame aperture and fastening the firstand second carriage bolts to the frame by frictionally engaging thefirst carriage bolt with a third washer and nut assembly andfrictionally engaging the second carriage bolt with a fourth washer andnut assembly, whereby the arm piece is releasably connected to theframe.
 20. A method according to claim 19, further comprising the stepof upholstering the arm piece such that the first and second carriagebolts remain exposed.